System and method for manufacturing products according to customer orders

ABSTRACT

A manufacturing facility for manufacturing products according to customer orders includes a kitting facility at which components are collected for a product in a customer order. The manufacturing facility also includes a build cell in which the component are assembled, configured, and tested according to the customer order to form a product. The manufacturing facility also includes a boxing facility at which the product is packaged. A transportation system transports the two or more components from the kitting facility to the build cell and transports the product to the boxing facility, whereby the product is assembled, configured, and tested in the build cell and packaged at the boxing facility.

RELATED APPLICATIONS

[0001] This application is a continuation-in-part of U.S. patentapplication Ser. No. 09/484,712 entitled Method and Apparatus forConsolidating Manufacturing of Devices filed by Mark D. Brown on Jan.18, 2000.

TECHNICAL FIELD

[0002] The present disclosure relates in general to methods and systemsfor manufacturing products. In particular, the present disclosurerelates to facilities and methods for manufacturing products such ascomputer systems according to customer orders.

BACKGROUND

[0003] Many years ago, manufacturers learned that, when buildingsufficiently large quantities of identical products, assembly linescould be used to increase production rates and decrease per-unitproduction costs. In an assembly line, the assembly process is dividedin a series of processing steps through which the work-in-process movesto result in the end product. These steps may be optimized, and once themanufacturing system becomes operational it will build a number ofproducts with the same configuration using the optimized steps.

[0004] Assembly lines are typically used in a build-to-stock productionmodel, where large quantities of identical products are manufactured inanticipation of forecasted demand. The manufactured products are thenwarehoused until that demand is realized. Build-to-stock manufacturingsystems are therefore primarily suited to markets in which manufacturerscan accurately predict customer demand.

[0005] In many markets, however, predicting customer demand is risky, atbest. For example, in the market for computer systems and related items,technological improvements are realized so frequently and componentprices change so rapidly that it is difficult to accurately predict howlarge the market for any particular product will ultimately be. As aresult, when manufacturers in industries like information technologyutilize the build-to-stock model, those manufacturers frequently findthemselves with stocks of manufactured goods that are difficult orimpossible to market at a profit (i.e., with stale inventory).

[0006] A contrasting model of production that helps manufacturers avoidthe stale-inventory problem is the build-to-order model. According tothe build-to-order model, each product is assembled only after acustomer has ordered that particular product. One of the disadvantagestraditionally associated with the build-to-order model, however, is thatmore time is required to fill orders, since products must bemanufactured, not simply taken from stock. Another disadvantage is thatbuild-to-order manufacturing systems are typically less efficient thanbuild-to-stock manufacturing systems, which drives up the cost ofproducts that are built to order. Accordingly, build-to-order systemshave typically been utilized in markets for luxury items, such astailored clothing, and markets in which a paucity of manufacturersleaves consumers with little choice but to bear the high prices anddelays that are generally passed down by build-to-order manufacturers.

[0007] Some manufacturers have attempted to minimize the delaysassociated with the build-to-order model by maintaining a significantinventory of the materials required for production (e.g., the componentsthat are assembled to create the finished goods). Simply carrying suchan inventory, however, imposes costs on manufacturers, including thecosts associated with warehousing the material. Furthermore, in marketswhere product innovations occur rapidly, such material oftentimes becomestale.

[0008] For example, in contemporary times, the market for computersystems (including, without limitation, mini-computers, mainframecomputers, personal computers, servers, work stations, portables, handheld systems, and other data processing systems) has been marked by highand increasing rates of product innovation. Further, to manufacture, forexample, a typical personal computer, many different components arerequired, including a processor, memory, additional data storage (suchas a hard disk drive), a number of peripheral devices that provide inputand output (I/O) for the system, and adapter cards (such as video orsound cards) for communicating with the peripheral devices. Each ofthose components is also typically available in many differentvariations. In such markets, even if using the build-to-order model,manufacturers risk significant losses when carrying significantinventories of material.

[0009] Also, it is difficult to optimize build-to-order manufacturingfacilities in terms of labor requirements and space requirements, assuch facilities must be able to produce of a wide variety of products.However, in markets where many manufacturers are competing forcustomers, such as the computer system market, any reduction inproduction costs that does not decrease product quality is an importantimprovement.

[0010] Among the cost-saving measures that a manufacturer may employ isto follow the direct-ship model, in which the manufacturer avoidsmiddlemen such as distributors and retailers by accepting ordersdirectly from and shipping products directly to customers. However,additional costs are borne by a manufacture that provides a direct-shipoption, in that the manufacture must provide distribution facilities, inaddition to providing the manufacturing facilities.

SUMMARY

[0011] The present disclosure relates to a manufacturing facility thatprovides build-to-order products and direct shipment of products tocustomers. More specifically, the present disclosure relates to amanufacturing facility that is constructed and operated in such a manneras to enjoy numerous benefits, relative to prior art manufacturingfacilities, including the benefit of reduced production costs.

[0012] According to the present disclosure, a manufacturing facility formanufacturing products according to customer orders includes a kittingfacility at which components are collected for a product in a customerorder. The manufacturing facility also includes a build cell in whichthe component are assembled, configured, and tested according to thecustomer order to form a product. The manufacturing facility preferablyincludes a boxing facility at which the product is packaged. Atransportation system transports components from the kitting facility tothe build cell and transports the product to the boxing facility. Theproduct is preferably assembled, configured, and tested in the buildcell and packaged at the boxing facility.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The present disclosure and its numerous objects, features, andadvantages may be better understood by reference to the followingdescription of an illustrative embodiment, taken in conjunction with theaccompanying drawings, in which:

[0014]FIG. 1 is a block diagram of a manufacturing facility forproducing products such as computer systems in a build-to-order fashion;

[0015]FIG. 2 is a block diagram of one embodiment of a manufacturingfacility according to the present disclosure;

[0016]FIG. 3 is a block diagram of the assembly unit of FIG. 2;

[0017]FIG. 4 is a generalized side view of portions of an exemplarytransportation system that brings kits to build cells and takesassembled products from build cells;

[0018]FIG. 5 is a block diagram illustrating a quadruplet of build cellsand portions of an associated transportation system according to FIG. 3;

[0019]FIG. 6 is a block diagram of various stations within a build cellaccording to FIG. 5;

[0020]FIG. 7 is a block diagram of a finishing station and associatedtransportation devices within the build cell of FIG. 6;

[0021]FIG. 8 is a block diagram depicting transportation devices thatservice multiple build cells among a quadruplet of build cells accordingto FIG. 5; and

[0022]FIG. 9 depicts a flowchart of an exemplary process formanufacturing products according to the present disclosure.

DETAILED DESCRIPTION

[0023]FIG. 1 depicts a prior art manufacturing facility 10 for buildingproducts according to customer orders and shipping products directly tocustomers. This particular manufacturing facility 10 is designed toproduce computer systems, which may be shipped to customers togetherwith associated articles, such as speakers, printers, docking stationsfor portable computers (e.g., advanced port replicators (APRs)),monitors, etc. The computer systems themselves are assembled fromcomponents such as motherboards, central processing units (CPUs), videocards, network cards, hard disk drives, floppy disk drives, CD-ROMdrives, memory, chassis, etc.

[0024] Manufacturing facility 10 includes an assembly unit 12, whichcontains a number of assembly lines where system assembly takes place ina series of operations. In particular, the components are transportedthrough and processed in at least five separate stations, beginning witha kitting station 20, where the components required for each system arecollected together to form a kit for that system. The kit of componentsis transported to an assembly station 22, where the hardware componentsare assembled to form the computer system. The computer system is thentransported down the assembly line to a burn-in station 24, wheresoftware is loaded onto the computer system and system tests areperformed. The system is then transported further down the assembly lineto a wipe-down station 26, where the system is cleaned and additionaltests may be performed. The computer system is then transported to aboxing station 28 within a shipping unit 30 of manufacturing facility10, where the system is boxed in preparation for shipping.

[0025] Shipping unit 30 includes an automated storage and retrievalsystem (ASRS) 32, a parcel unit 34, and a less-than-trailer load (LTL)unit 36. Relatively small orders are shipped to customers via parcelcarriers through parcel unit 34, and larger orders are loaded ontopallets and shipped to customers via LTL carriers through LTL unit 36.

[0026] Referring now to FIG. 9, there is illustrated an exemplaryprocess in accordance with the present disclosure for manufacturingproducts according to customer orders. Referring also to FIG. 2, thereis depicted an exemplary manufacturing facility 40 according to thepresent disclosure. In the exemplary embodiment, manufacturing facility40 is used to manufacture computers, which are shipped directly tocustomers, along with associated articles (such as monitors, etc). Aspreviously noted, manufacturing facility 10 also manufacturers anddirectly ships computers to customers. However, as described below,manufacturing facility 40 is operated according to a new process andincludes significant architectural enhancements, new hardware, and newcontrol logic that provides increased quality and efficiency.

[0027] The exemplary process begins at block 150 of FIG. 9, withassembly facility 40 beginning a production cycle. First, themanufacturer receives one or more customer orders (block 152). Then, themanufacturer orders from suppliers any components needed to manufacturethe products for the customer orders and any articles, as well as anypackaging (such as boxes and protective inserts) needed to fill thecustomer orders (block 154). Preferably, to minimize the inventorycarried in manufacturing plant 40, few if any components, articles, andpackaging will be left over from previous production runs. Therefore, atthe beginning of each production run, most or all of the components,articles, and packaging for the orders in that run will be ordered fromsuppliers. Production runs may nevertheless overlap to some degree, inthat the manufacturer need not wait until the last item for one run isshipped before placing orders with suppliers for components for the nextproduction run.

[0028] As shown at block 156, manufacturing facility 40 then beginsreceiving the ordered the components, articles, and packaging.Specifically, manufacturing facility 40 preferably resides in a buildingthat includes an assembly unit 42 in one region (illustrated near thebottom of FIG. 2) and a shipping unit 44 in another region (illustratednear the top of FIG. 2), and the product components are received inassembly unit 42, via docks (not expressly illustrated) in a portion ofthe left wall 45. By contrast, packages for assembled products enterassembly unit 42 through a portion of the right wall 47.

[0029] Assembly unit 42 preferably includes three distinct sections: akitting facility 50, a build facility 52, and a boxing facility 54.Further, the three sections are preferably disposed as illustrated inFIG. 2, with kitting facility 50 and boxing facility 54 situatedadjacent to exterior walls 45 and 47, and build facility 52 situatedbetween kitting facility 50 and boxing facility 54.

[0030] With reference to FIG. 3, in the illustrated embodiment, kittingfacility 50 includes a number of kitting lines 56. Each kitting line 56preferably contains one or more racks 60. When the components arereceived, they are preferably placed in racks 60. Once sufficientcomponents have been received, particular orders are selected forfulfillment, and the process of building particular computers in thoseorders is initiated.

[0031] In the illustrated embodiment, that process begins with a bill ofmaterial or traveler being printed for a particular computer in aselected order. The traveler is a document that uniquely identifies thespecific product such as a computer throughout the assembly process. Thetraveler preferably includes a barcode with the identifying information,as well as a list of the specific components that are to be picked andassembled. Preferably, the traveler is printed at the end of kittingline 56 furthest from wall 45 and is placed in a container and scannedwith a first traveler scanner 62. The container (not shown) may also bereferred to as a tote. That end of kitting line 56 preferably alsocontains a tote return device 64, from which each tote is preferablyobtained.

[0032] After the traveler is scanned, a conveyor 66 in the kitting linemay carry the tote past racks 60, in a direction towards wall 45.Conveyor 66 may be part of a material-control system that includes orotherwise communicates with other systems or subsystems, such as akitting-management system. Movement of the tote containing the travelermay be initiated by pressing a particular button in communication withthe kitting-management system, for example. First traveler scanner 62,as well as other input and output devices, may also communicate with thekitting-management system.

[0033] As conveyor 66 carries the tote by racks 60, one or moreoperators 68 (preferably more) pick the required components from racks60 and place those components into the tote (block 158). The process ofcollecting the components to be used in assembling a particular productmay also be referred to as kitting, and the collected components may bereferred to as kits. Lights may be situated near particular componentson racks 60, and the kitting-management system may automaticallyilluminate particular lights to indicate which components should bepicked. In addition, picking operations may be monitored by means ofpicking scanners (not illustrated), which scan barcodes on (orassociated with) the components being kitted.

[0034] The largest components with the greatest demand (e.g., computerchassis) are preferably located at the end of kitting line 56 nearestwall 45, in order to minimize the amount of material movement requiredwhen restocking those items. Accordingly, in the illustrated embodiment,all components but the chassis are picked as the tote travels towardswall 45. A system tray is then retrieved from a tray-return device (notillustrated) and placed on top of the tote, and then a chassis isretrieved from a stock of chassis 70 and placed on the system tray.

[0035] After all of the required components have been picked, a secondtraveler scanner 72 may be used to scan the traveler. Thekitting-management system and the material-control system may utilizethe data from that scan to track movement of and update statusindicators for the components individually and the tote as a whole. Thetote may then be lifted by a tote elevator 74 to an overheadtransportation system 76, which automatically transports the tote tobuild facility 52 (block 160). As described in greater detail below, thecomponents will be assembled in build facility 52 and the product willthen be transported to a boxing line 90 within boxing facility 54 to bepackaged.

[0036] In the illustrated embodiment, build facility 52 includes anumber of build cells 78 within which assembly occurs, and those buildcells 78 are preferably arranged in one or more groups of four. A groupof four build cells may be referred to as a quadruplet of build cells80, or simply a cell quad 80. In FIG. 3, four cell quads 80 are shown,along with two transportation systems 76, with two cell quads 80situated in series along (and preferably below) each of transportationsystems 76. In addition, two kitting lines 56 and two boxing lines 90are shown. In the illustrated embodiment, each transportation system 76links one kitting line 56 with two cell quads 80. Preferably, both oftransportation systems 76 discharge the products onto a recirculatingconveyor (or loop) 81, and each product is then automatically pulledfrom recirculating conveyor 81 onto any of boxing lines 90 that is notalready busy.

[0037] In alternative embodiments, however, different numbers oftransportation systems, kitting lines, build cells, and boxing linescould be utilized. For example, four transportation system could beprovided, two kitting lines could merge onto one or more of thetransportation systems, six cell quads could be disposed along eachtransportation system, and the boxing facility could include six boxinglines.

[0038] Referring now to FIG. 4, in the illustrated embodiment, eachtransportation system 76 includes three distinct transportation devices:an incoming conveyor 82, a tote return conveyor 84, and a outgoingconveyor 86. Incoming conveyor 82 transports totes with components tobuild cells, tote return conveyor 84 transports empty totes from buildcells back to tote return device 64, and outgoing conveyor 86 transportsproducts from build cells to boxing facility 54.

[0039] With reference to FIG. 5, an exemplary cell quad 80 is depicted,including four build cells 78A, 78B, 78C, and 78D, with each of thebuild cells disposed adjacent to two others. As shown, incoming conveyor82 preferably includes two staging areas or spurs 88A and 88B for eachcell quad 80, and the material-control system may automatically divertthe incoming totes onto one of incoming spurs 88A or 88B, based on adetermination of the optimum build cell for assembling the particularproduct such as a computer. For example, the determination could be madebased on which build cell had the most capacity for additional work,which build cell had gone the longest without receiving work, whichbuild cell had all of the tools necessary to build the particularproduct, or a combination of these and/or other factors. Likewise,outgoing conveyor 86 preferably includes two outgoing spurs 92A and 92Bfor each cell quad 80, for receiving products from that cell quad 80.

[0040] Specifically, in the illustrated embodiment, spurs 88A and 92Areceive totes coming to and products coming from (respectively) the twobuild cells situated to the left of transportation system 76 (i.e.,build cells 78A and 78C). Similarly, spurs 88B and 92B receive totescoming to and products coming from (respectively) the two build cellssituated to the right of transportation system 76 (i.e., build cells 78Band 78D).

[0041] In the illustrated embodiment, cell quad 80 includes tworeceiving apparatuses 94A and 94B, with receiving apparatus 94A movinglaterally between build cells 78A and 78C and receiving apparatus 94Bmoving laterally between build cells 78B and 78D. Receiving apparatus94A lowers each tote from spur 88A and 88B into the build cell that wasdetermined to be optimum build (as described above) and lifts productsfrom build cells 78A and 78C to spur 92A of outgoing conveyors 86.Receiving apparatus 94B performs corresponding functions for the cellsand spurs on right side of transportation system 76. Receivingapparatuses 94A and 94B may be implemented as multi-axis elevators, eachcapable of moving material along a vertical axis and two horizontalaxes, and receiving apparatuses 94A and 94B may perform other functions,in addition to the functions described herein.

[0042] After the tote is deposited in the selected build cell, thecomponents are assembled, configured, etc. (block 162), as described ingreater detail below with reference to FIG. 6. The product is thenreturned to transportation system 76, transported to boxing facility 54(block 164), and packaged (block 166). The packaged product may then betransported to shipping unit 44 (block 168). The process described abovemay be repeated numerous times (with additional material possibly beingreceived, additional products being built, etc.), and the processpreferably ends at the scheduled termination of the production run, asindicated at blocks 170 and 172.

[0043] Referring now to FIG. 6, build cell 78D is depicted in greaterdetail. Build cell 78D preferably includes a build station 100, a burnstation 120, and a finishing station 140. Build cell 78D may alsoinclude additional stations, such as a quick-test station 160.Preferably, many of the build cells include the same features, but thosefeatures are preferably arranged differently, so that opposite buildcells are substantially mirror images of each other.

[0044] In the illustrated embodiment, two operators A and B assemble thecomponents from the tote. Thassembled components may then be moved toquick-test station 160 for a brief operational test and then to burnstation 120 to have software installed and/or configured and moreextensive tests performed. Then, the assembled components may be movedto finishing station 140, to be cleaned and inspected, for example totest for compliance with Federal Communications Commission (FCC)regulations regarding electromagnetic radiation (EMR). Finishing station140 may also be referred to as a wipe-down station. Additionalprocessing (such as additional software installation or configuration)may also be performed at finishing station 140, for example for orderswith special or unusual requirements. After the finishing operations arecompleted, the assembled product such as a computer (which may then beconsidered a product) is returned to transportation system 76 fortransport to boxing facility 54. The product may also be referred to asa finished product. Operators C and D may cooperate in performing theburn-in and finishing operations, possibly with additional assistancefrom operators A and/or B.

[0045] With reference now to FIG. 7, a portion of finishing station 140is depicted in greater detail. Specifically, two monitors 142 and twocorresponding finishing trays 144 are depicted. Also shown are afinishing conveyor 146, an exit conveyor 148, and a computer 147situated on one of finishing trays 144. Exit conveyor 148 may also bereferred to as a removal apparatus.

[0046] Computers from burn station 120 may be received by finishingconveyor 146 and automatically conveyed to an available one of finishingtrays 144. A corresponding monitor 142 may then be connected to thecomputer for any finishing operations that require an operator tooperate the computer.

[0047] In the illustrated embodiment, finishing conveyor 146 and exitconveyor 148 are aligned vertically to conserve space, with finishingconveyor 146 receiving computers at an upper level and exit conveyor 148taking computers away at a lower level. In alternative embodiments,however, the exit conveyor may be above the finishing conveyor.Preferably, electrical controls (e.g., toggle switches or push buttons)allow operators to move finishing trays 144 between the two levels.

[0048] Further, one finishing conveyor and one associated exit conveyorare preferably disposed between pairs of adjacent build cells. Forexample, with reference to FIG. 8, in the illustrated embodiment,finishing conveyor 146A and a corresponding exit conveyor (not expresslyshown) are disposed between, and shared by, build cells 78A and 78B.Likewise, finishing conveyor 146B and a corresponding exit conveyor (notexpressly shown) are disposed between, and shared by, build cells 78Cand 78D. By providing one set of finishing and exit conveyors for eachtwo build cells 78 (rather than one set for each build cell 78),additional savings may be realized with respect to space and capitalinvestments for equipment.

[0049] Nevertheless, in the illustrated embodiment, each build cell 78includes a staging area 149 for products, and exit conveyors 148 depositeach product onto the particular staging area 149 that corresponds tothe finishing tray 144 from which that product was obtained. Thus, if acomputer was finished in build cell 78D, exit conveyor 148 would stagethat computer on the staging area 149 for build cell 78D. Receivingapparatus 94B may then move the staged computer from that staging area149 to outgoing conveyor 86.

[0050] In the illustrated embodiment, as is done in kitting lines 56, inboxing lines 90 the amount of material movement required when restockingis minimized by keeping the largest materials with the greatest demand(in this case, the boxes 200) at the end closest to the exterior wallthrough which those materials are received (in this case, wall 47). Anelevator 202 may automatically lower products to a working level, andeach product may be placed into a box 200.

[0051] The products may be kept on the system trays while being builtand transported to boxing. When a product is hoisted into box 200, theassociated system tray may then be transferred to a tray return device(not illustrated). The system tray may then be automatically transported(e.g., by tote return conveyor 84) back to kitting line 56 for reuse.

[0052] After receiving the computer, box 200 may be transported by aconveyor past picking racks 204 towards build facility 52, andadditional items (such as power cords and manuals) may be retrieved frompicking racks 204 and added to box 200. Scanners may be used to trackwhich items have been added to box 200. Box 200 may then be closed andtaped and a tracking label applied. Box 200 may then be lifted by anelevator 206 and discharged onto a distribution conveyor 210, to becarried into shipping unit 44. The tracking label may be scannedautomatically when box 200 is on its way out of boxing facility 54, toprovide additional information to the material-control system regardingmaterial/product location and status.

[0053] As will be evident to those of ordinary skill in the art, amanufacturing facility according to the present disclosure may enjoynumerous benefits, relative to prior art manufacturing facilities. Forexample, the architecture, equipment, and control systems used in theassembly unit of the present disclosure provide for substantiallyincreased productivity and quality, while decreasing the space and laborrequirements, relative to prior art facilities. Overall production costsmay therefore be substantially reduced.

[0054] In addition, the architecture provides for efficient operationwhile operating at full capacity and while operating at reducedcapacity, in that portions of the facility can be deactivated orbypassed without affecting the performance of other portions. Themanufacturing facility can also be used to build a wide range ofdifferent products during a single production run without sacrificingefficiency or quality.

[0055] Furthermore, although the present invention has been describedwith reference to an illustrative embodiment, various alternativeembodiments are also contemplated. For example, although theillustrative embodiment relates to a facility for manufacturing computersystems, many aspects of the disclosed architecture, equipment, andprocess could be utilized to advantage in producing other types ofproducts.

[0056] Those with ordinary skill in the art will understand thatnumerous additional variations of the illustrative embodiment could bepracticed without departing from the scope of the present disclosure.The present invention is therefore not limited to the specificallydisclosed embodiments but is defined by the following claims.

What is claimed is:
 1. A manufacturing facility for manufacturingproducts according to customer orders, the manufacturing facilitycomprising: a kitting facility at which components are collected for aproduct ordered by a customer; a build cell in which the components areassembled, configured, and tested to form the product; a boxing facilityat which the product is packaged; and a transportation system thattransports the components from the kitting facility to the build cellwhere the components are assembled, configured, and tested, and thattransports the product to the boxing facility where the product ispackaged.
 2. The manufacturing facility of claim 1 , further comprising:at least first and second build cells, each having at least onefinishing tray, the second build cell disposed adjacent to the firstbuild cell; and one removal apparatus that services the first and secondbuild cells by receiving products from the respective finishing traysand staging the products for removal from the first and second buildcells.
 3. The manufacturing facility of claim 1 , further comprising:first and second build cells with the first build cell is disposedadjacent to the second build cell; and one receiving apparatus thatservices the first and second build cells by receiving, from thetransportation system, a first set of components for the first buildcell and a second set of components for the second build cell.
 4. Themanufacturing facility of claim 3 , further comprising: a quadruplet ofbuild cells including first, second, third, and fourth build cells withthe first build cell disposed adjacent to the second build cell and tothe third build cell; a first receiving apparatuses that services thefirst and second build cells; a second receiving apparatus that servicesthe third and fourth build cells; a first removal apparatus thatservices the first and third build cells; and a second removal apparatusthat services the second and fourth build cells.
 5. The manufacturingfacility of claim 4 , wherein the transportation system furthercomprises: an incoming conveyor that transports components from thekitting facility to the build cells; and an outgoing conveyor thattransports products from the build cells to the boxing facility; theincoming conveyor and the outgoing conveyor aligned generally verticallyalong a conveyance line extending substantially from the kittingfacility to the boxing facility; and the manufacturing facility havingtwo or more quadruplets of build cells disposed in series along theconveyance line.
 6. The manufacturing facility of claim 5 , comprising:two or more conveyance lines; and two or more quadruplets of build cellsdisposed in series along each of the conveyance lines.
 7. Themanufacturing facility of claim 1 , wherein the transportation systemfurther comprises: a first transportation unit that transports thecomponents from the picking facility to the build cell; and a secondtransportation unit that delivers the product to the boxing facility. 8.The manufacturing facility of claim 7 , wherein the build cell comprisesa transportation device that transports the product from the build cellto the second transportation unit for delivery to the boxing facility.9. The manufacturing facility of claim 8 , wherein the first and secondtransportation units further comprise: an incoming conveyor and anoutgoing conveyor, respectively, aligned generally vertically; and thetransportation device operates below the incoming and outgoingconveyors, such that space within the manufacturing facility isconserved.
 10. The manufacturing facility of claim 9 , wherein the buildcell further comprises: a build station at which the components areassembled; a burn station at which the assembled components areconfigured; and a finishing station at which the assembled componentsare transformed into a product.
 11. The manufacturing facility of claim10 , wherein the finishing station further comprises: at least onefinishing tray; a finishing conveyor that transports the assembledcomponents to the at least one finishing tray; and an exit conveyor thattransports the product to the transportation device for removal from thebuild cell.
 12. The manufacturing facility of claim 11 , furthercomprising: the finishing conveyor and the exit conveyor alignedgenerally vertically to conserve space within the manufacturingfacility.
 13. The manufacturing facility of claim 1 , further comprisinga distribution facility that provides for shipping the product from themanufacturing facility to a customer, in accordance with the customerorder.
 14. A method for manufacturing products according to customerorders, the method comprising: collecting components at a kittingfacility for a product ordered by a customer; transporting thecomponents from the kitting facility to a build cell; assembling,configuring, and testing the components in the build cell to form aproduct; transporting the product to a boxing facility; packaging theproduct at the boxing facility.
 15. The method of claim 14 , furthercomprising: transporting a first product from a finishing tray of afirst build cell to a first staging area, via one removal apparatus; andtransporting a second product from a finishing tray of a second buildcell to a second staging area, via the one removal apparatus; and movingthe first and second products from the first and second staging areas toa transportation system.
 16. The method of claim 14 , further comprisingreceiving sets of components from a transportation system for first andsecond build cells, via one receiving apparatus.
 17. The method of claim16 , further comprising: receiving sets of components from thetransportation system for third and fourth build cells, via a secondreceiving apparatus; transporting products from finishing trays of thefirst and third build cells to first and third staging areas, via oneremoval apparatus; and transporting products from finishing trays of thesecond and fourth build cells to second and fourth staging areas, via asecond removal apparatus.
 18. The method of claim 14 , wherein the stepof transporting the components from the kitting facility to the buildcell comprises transporting the components to the build cell via anincoming conveyor that is aligned generally vertically with an outgoingconveyor that transports products from the build cells to the boxingfacility.
 19. The method of claim 14 , wherein the step of assembling,configuring, and testing the components in the build cell comprises:assembling the components at a build station of the build cell;configuring the assembled components at a burn station of the buildcell; and transforming the assembled products into the product at afinishing station of the build cell.
 20. The method of claim 19 ,further comprising: transporting the assembled components to a finishingtray of the finishing station, via a finishing conveyor; andtransporting the product from the finishing tray to a transportationdevice, via an exit conveyor, for removal to the transportation system.21. The method of claim 14 , further comprising shipping the productfrom the manufacturing facility to a customer, in accordance with thecustomer order.